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Malcolm's Race Car Build

368K views 1.5K replies 188 participants last post by  SWicklow  
#1 · (Edited by Moderator)
Background;
I have had my MSA licence since 1993 and I hill climbed and sprinted my GTD40 for 15 years. Whilst doing that I have had a Lotus 51 (1968 FF), a Prosport 3000 spyder as track toys, and also did a couple of Britcar 24 Hour races in a Porsche 993 RS. But what turned me to MX5s was being invited to race in the USA in the 13 hour races at Virginia International Raceway in a Spec Miata which I did for 4 years running highlighting with a 4th place finish in 2008 in class of 30 cars with a grid of 90 cars. I did start the last lap (after 13 hours remember) in 3rd position but ran out of fuel with one ******* mile to go and so came 4th just a measely 5 seconds behind 3rd place! I still get bad dreams about that on! But as a result I am now addicted to MX5s and compared to my other toys it is the best value for money car out there and just brillaint fun. I still like the other cars (it will be hard to beat the feelings of the Prosport 3000 going into the esses at Silverstone flat out in 5th and only half way through braking and going down to 3rd for the exit on to hangar straight) but the 5 puts a big smile on my face!

So I bought an ex Paul Sheard MAX5 car and ran that for a season in the Future Classics with CSCC back in 2008 (season result was 3rd in class) and then sold the car with a plan to build a specific car for the series, built my way and with all that I have learnt about race car prep being used, budget permitting. Budget is already out of control so for this thread costs are not really up for discussion if ok with you lot! :) Also there may be the odd racer secret I wish to keep to myself so I may not reveal all the tricks although I hope you will find me reasonably open as to what I am doing. Afterall you cannot hide the obvious and also, I don't believe in cheating.

You may have seen other posts I have made elsewhere on this forum regarding what I am doing but the idea now is to group it all together, and as soon as I suss out pictures I will post some up.

So where I have I got to now?

Firstly I bought an unused shell from a MX5 specialist breaker up near Donnington. I was going to buy two unused shells but someone beat me to the other one by a matter of days! The shell had been part of a car that had been used as an arcade game console! All controls had been hooked up to a computer with a big screen in front and it had done 186,000 kms without turning a wheel so in theory the chassis is very straight, although with kids clambering all over it the panels were not great. I also bought a crashed car as a donor vehicle for parts as over the course of the project I would need a lot of little stuff that is just crazy to buy separately. With left over parts from my last race season the project is now a flyer.

The bit I like at present is specifiying what I am to do with this car. The principles I learnt from my seaon in a standard MAX5 car is that whilst super good in corners and under braking, it is way down on power. So the target of lightweight and more power were set early on. Then it is buy buy buy parts and they have been flowing in.

Parts already here include (amongst others)

Close ratio gear set from Quaife (a custom mix of the two available sets to suit my ideas)
Gaz dampers and springs
Race Technologies DASH2 and DL1 logger system
Race steering wheels (more than one required for different expected driver positions and shapes of drivers)
Wilwood 4 pot brakes all round on 11 inch discs
Poly suspension bushes
different ratio diffs to allow gearing changes for different circuits (just need a 4.3 to complete the set if you have one spare!)
light weight hard top
drivers door window net
FIA spec welded in cage

Parts on order include a normally aspirated race engine from Rebello Racing in California.

Parts being worked on now include tubular suspension arms and a long range fuel tank. The chassis is away being dipped (at Surface Processing Ltd) with some more seam welding and other ideas to be done by Southern GT then back for e-painting and then the assembly really starts.

I took quite a lot off the car as when it went for dipping, with its cage fitted already, it weighed 248 kgs. No idea how that compares to an unmodified chassis.

My aim for this year is to take part in one race at the end of the season plus a couple of shake down track days or test days. Full season next year plus also going to Europe for some longer races and once confidence in the car is there, to take it to USA for another crack at the 13 hours.

If you want to see the story I wrote after my first trip to the States follow this link;

http://www.gt40s.com/images/VIR2005.pdf

However this thread will be worthless unless I can post pictures! I can see the insert image button and also the insert link button. Can someone remind this numbskull how to simply post pictures?
 
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#2 ·
will be worthless unless I can post pictures! I can see the insert image button and also the insert link button. Can someone remind this numbskull how to simply post pictures?
Get a Photobucket account and upload the images there. Then simply copy the image link for that picture and paste it into a post on here.
 
#5 ·
hi Matt,

No, no MAX 5 or Ma5da for me I am afraid. No way would this car be called legal to their regs! CSCC is the UK stuff I am interested in plus longer races abroad in due course. And whilst I have had an MSA license since 1993 I have only circuit raced for 5 years so do not call myself experienced really compared to some. And certainly not to the current MX5 racers out there who know their cars way more than I do, from years of racing the same car. Good luck with your racing this year, post your stories on the forum, they would be good to read. Nothing beats racing!
 
#12 · (Edited by Moderator)
Ok Lets see if these pictures come out......

Firstly other rides of mine over the years.

This is my GTD at home when being featured in a magazine. Never saw the article printed but they gave me the pictures anyway. Next day I took the car to the Le Mans Classic and filled in up with rain and La Sarthe sand!

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If you want to see that car in action follow this link from 2 days at Spa in Sept 2009



Shortly after I got marrried, I bought my wife this Little Lotus 51c. It is a formula ford car but it was tuned to 160 bhp which works out at 400 bhp per ton. And with these big F1 style wheels on, it looked great. Now sold. This picture is Wendy driving at the Brighton Speed Trials, an event I did for 15 years on the trot, mainly in my GTD. The Lotus was good for a 11.8 sec 1/4 mile.

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Then I bought a Prosport 3000. These cars were recently uninvited from the Historic Group C series as they were beginning to beat the proper Group C cars and that is not on really! When on song and driven well, they could do 1 min 50 laps of Silverstone GP circuit. Same as a Silk Cut Jaguar or Porsche 956. Cheap (ish) to buy but criminal to run. Now sold. Gave me Tinitus as a farewell present as flipping loud. But oh the G forces.....

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Then I had my white MAX5 car which we had great fun in. This picture is from Mallory and we got our best result of the season with 3rd overall that day. Damp and twisty circuit just played into my hands. Now sold.

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This one is of me in the Porsche 993 (not mine) during the Britcar 24 Hours in 2006. Came nowhere but it was fun and I got paid to drive! Made some good freinds from that event and I ended up being converted to Porsche ownership with a 996 C4S.

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#16 ·
Thanks for straightening me out there with the pictures, I really made that look difficult! Is there an optimum minimum size for resolution on pictures that look good but don't take up so much memory for just looking at on the web? On other forums I typically use 640 by 480 or something close to that.

Getting back on track with this thread, here is a picure of my car as I last saw it at Surface Processing Ltd. They just lifted it of the trailer! Not very heavy then.

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Then the most current shot of the car

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#19 ·
Thanks for straightening me out there with the pictures, I really made that look difficult! Is there an optimum minimum size for resolution on pictures that look good but don't take up so much memory for just looking at on the web? On other forums I typically use 640 by 480 or something close to that.
the forum automatically re-sizes to stop you having to scroll left/right when images are too large.

IMO 640x480 is far too small, post as big as you like, at least then you can click on the image and see it in high quality. It's 2010 if you don't have broadband an a 21" monitor, well then it sucks to be you
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#21 ·
Fanfooooooooooooooooooookintastic.

Me fave thread
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#22 ·
Just seen this thread Malcolm. I have a steel shell (not a Mazda, a Nissan), I'd like to have stripped and was considering using Surface Processing, will you having the shell dipped by them once stripped? I have seen some shells that are beautifully prepared but not dipped in primer that have deteriorated within months due to moisture ingress in box sections and seams. Their dipping option is supposed to alleviate this potential issue. Safety Devices say they are excellent people but definitely recommend having the shell dipped in primer rather than just sprayed. Good luck with it!
 
#29 · (Edited by Moderator)
Sorry missed this question from earlier.

Yes once I have have the car back to bare metal, it will come home for some work to be done on it and then go back for a secondary dip to remove any new crud and surface rust that reoccured and then go for what they call e painting. This is a dipping process not a spray on process. I have had to drill holes to ensure proper drainage and these will have to be welded up later. Kinda defeats the object of dipping and painting if you then have to weld up holes but because the process is a hot dip process it sucks liquid into holes that are really tiny and so if it got into any tube or enclosed space it then causes issues later. You have to use 4-5mm holes to ensure proper drainage as otherwise the surface tension will retain liquids. Because the e paint is really a sealant/undercoat rather than a finish coat welding up some holes is annoying but not the end of the world.

If you go to the Surface Processing web site you can watch videos of the whole process. They are pretty much the only guys in the country who do this. I looked quite hard and couldn't find any one else who did this proccess. I stand to be corrected! :)

Yes I have removed the OEM fuel tank and cut the blister off that housed it. I have plans to put in a larger ali fuel tank for endurance racing. I don't expect more than 10 mpg out of this car and should this car make it to the start of an endurance race I wish to go up to or beyond 2.5 hour stints. When in Spec Miata we were going up to 1 hour 40 minute stints on a standard 45 litre tank. But that was getting marginal and as you may know I have run out of fuel on the last lap after 13 hours of racing before and don't wish to have it happen again.

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I was being lent on by my US mates to fit a Nascar fuelling system which would refuel 12 gallons in 5 secs but that was $1000 I don't have (and that is a for a used system). In the Britcar refuelling you have to use standard fuel pumps for refuelling not dump cans or dry break systems anyway so no real gain there. However the filler cap will be moved onto the drivers side to allow for better access in pits stops so that any refueller does not have to run around the car which is safer and quicker. I have to remake the fuel filler area anyway so which side is irrelevant. May even make it central through the boot lid. No decision firm on that yet. However I do have to repanel the fuel tank area so it is firewalled from the drivers compartment so a bit of fiddling to do coming up around that rule.

An interesting refuelling rule used at VIR was that if any fuel was spilled onto the ground if the puddle or stain on the ground was more than 12 inches in any one direction, you got a drive through penalty. One more thing to bear in mind......

Inner Flitches? Not sure what you mean here. Is that the frog plates or whatever they are called? I suspect not at this stage although I have a design in mind to reinforce the ARB mounts as I have heard of those collapsing under big loadings.
 
#26 ·
Andy Robinson Racing did the cage for me. He is a specialist in this field and also on committees for the MSA with regard to Drag Racing but also advises on roll cages. This cage is an FIA/MSA approved cage to suit my needs and purposes. It is designed to go under my hard top (which is a lightweight hard top) and the cage is also responsible for holding the roof onto the car as well. Therefore no heavy fixings as per standard roof fitments. 4 * M6 nuts and bolts for me. I am not as worried about water tigtness as some might be so no rubber seals used except for the front leading edge of the roof.

I had bought a Safety Devices cage to use. A bolt in design. That weighed in at 52kgs. This one is big smile inducing lighter! And I think a far superior design. We looked at the cages used in the states, other custom cages used in some drift cars, the safety devices item and then picked all the best bits and features, combined that with Andy's huge experience of cage building to come up with this cage. Andy prices his cages according to the number fo fixing points and extras, eg I had the hard top mounts built in and also a drivers net fitted. I consider safety a high priority so the investment is worth it to me. But it was not shockingly expensive, so Russell, phone Andy and talk to him. If he is outrageous in pricing now then I got even better value for money than I think I did!

The side impact bars do mean you have to gut the doors of your car. Really gut them. Doors are heavy so I was really happy to do this and am still looking at them for ways to reduce their still heavy weight (in my eyes) some more. I have discounted carbon as the quotes were too high for now.

This cage also required the complete removal of the dash board and cross bar, plus the rear parcel shelf and other bits and bobs of metal around the place. Being welded in and stitched to the shell in numerous places, not just up the windscreen frame, should mean overall stiffness is well up. I did think of going through the front bulkhead to the top mounts of the front suspension. I did not as the gain was percevied to be slight compared to the cost and effort. But it would be easy to come back to that later if I think it neceesary after testing. All that I have spoken to with cross bracing in the engine from one top mount to the other have said it had only a small effect. And their cars would not be as stiff as this one will be as a starting point. So I am leaving it there on cage and struts for now but you can see some seam welding has been done, in accordance with the FM recommendations, but having the car dipped will allow me to easily get some extra seam welding done in places not normally available for it. Trying to seam weld pre dipping was difficult.

Being six foot tall did create problems in meeting regulations on head clearance to the roof and cage structure. I had a custom carbon seat made, based on one from a Panoz so I am told, with ali mounts so that the seat touches the rear bulkhead and the floor at the same time. I also moved forward the chassis rail that OEM seat mounts bolt on to forward by about 8 inches. This allows fitting of runners to the seat so that when in multi driver mode the seat can be slid back and forth but without lifting the driver. This may not be that clever a decision as short drivers not only have short legs, but shorter torso's so when checking that the wife can drive the car she was so low down that she could not see the bonnet at all. Ooops! Might have to put legs on the front of the mounts after all. The seat is very comfortable and stiff, and also very light. The carbon element was about 2.7 kgs but haven't weighted it with seat mounts on yet. For now using OEM runners when needed.

As to final weight of the car, that is a bit of guesswork right now. But my MAX5 car was 865 kgs ex driver and so I should easily beat that figure. Currently the car weighs 248kgs but there are a few bits missing......
 
#28 ·
nice read malcolm.

do you remove the oe tank and use an alloy tank sunk in the boot floor.. is that fm regs..?

also are you bracing the front out ie inner flitches..?

michael
 
#30 ·
Can you not just leave the holes you drill for drainage and bung them? May actually be good to leave them to drain rain water. Water getting trapped is why the 5 rusts normally in the first place
 
#33 ·
I'm talking to my fibreglassers about doors, so I'll let you know on that front, won't be cheap but will be a steal compared to carbon. The other option for doors is the guy in Sweden on Clubroadster, I think he wanted ?500 a door? Nice and light, but shipping could cost a lot, and they are very rough as far as the shape is concerned!

Russell.
 
#34 ·
Do let me know the door cost, but can't guarantee I will be in for some at this stage. ?500 per door for fibreglass is way too high for me. I think when I looked into racing specific carbon parts ie bonnet, boot, and doors I was looking for others to buy in with me at ?2,500 for the set. There was not enough take up interest shown for me to justify the mould costs and gamble that everyone would pay up when push came to shove. Whilst on the carbon front, in the series I wish to race in, it may be that if my car is too successful (not a certainty by any stretch of the imagination!), a logical step to make the racing more fun again would be to ban carbon body panels. A risk I was not wanting to take.

On the steel door front, if I remember rightly an OEM door with glass weighs about 18/19 kgs. Currently mine weigh about 9 kgs sans any glass. I have a scheme to reduce that further once they are back from dipping. But each peice of door I remove makes them more twisty. So my plans are a compromise between light weight and the door falling to peices at speed! I am going to be fitting polycarb windows in due course.
 
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